Mobile manufacturing plants for producing prefab elements

ABSTRACT

The present invention concerns a mobile plant for producing prefab elements for the building industry. The mobile plant comprises a covering canopy structure (A) that can be dismantled, such as a large tent or a hall, assembly tables ( 1, 1.1, 1.2, 1.3 ) for producing elements in brick material and mortar, an installation ( 14 ) for preparing the reinforcing irons for the panel elements of brick and mortar, a concrete mixer plant ( 3 ) for supplying the mortar, and/or a plant for generating auxiliary means (steam, electric current, compressed air, etc.) and/or a service container ( 7 ) for the personnel and for managing the plant. All these equipment elements are mounted on trailers and/or in containers that can be transported by road or by rail to the building site or the buildings to be erected. The main advantage of the mobile plant is seen in the maximum work rationalisation that yields considerable savings in time and in means.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention concerns an autonomous manufacturing plant, called“mobile plant” in the following, for producing prefab elements,according to the introductory part of the claim 1.

2. Discussion of Background Information

The term prefab elements in this context is understood in particular asbuilding elements of brick material and cement mortar for producingpanels for the building industry (residential and industrial buildings)such as e.g. described in the European patent application EP-01810973.6published as EP-1273729 A2 on the 21 Aug. 2003.

SUMMARY OF THE INVENTION

In this specific case elements of brick material are concerned that canbe assembled, using reinforcing irons and cement mortar filled in, toform the most different types of prefab structures (box-type structures,walls, floors or ceilings, etc.).

It is to be underlined that the mobile plant described and claimed herein general is apt to produce “on the building site” just about everytype of prefab structure consisting of elements of brick material (ortile material) interconnected using cement mortar in order to form arigid structure of any form and application desired.

The “mobile plant” thus is created as required for the task, apt togenerate a large number of prefab elements in real time, and to reducecost of transport of materials.

A new technology for high quality is concerned here, apt to activate a“door to door” industrial process directly on the building site wherethe buildings are to be erected.

It represents the realisation of matured direct experience in the fieldof prefabrication, for the benefit of all users, manufacturers andengineers.

The validity of the inventive idea can be comprehended also from thefact that the structures used in the present prefab elementmanufacturing practice were made use of in stationary and permanent workenvironments (e.g. halls), where the only advantage was gained from therepetition of the elements produced, but where the problems of transportand of assembly could not be dealt with. The present invention aims ateliminating all the problems once and for all concerning transport to,and assembly of the prefabricated elements on, the building site wherethe planned building is to be built.

For realising these objectives the inventive mobile plant ischaracterised in that it comprises a whole series of equipment devices,required in their combination, which constitute the characterising partof the claim 1. In its general concept the mobile plant thus comprises acovering canopy or roof erected temporarily, i.e. just for the timerequired for producing the prefab elements in close vicinity of thebuilding site where the planned building is to be realised, under whichcanopy the equipment indispensably required for manufacturing theelements is placed. The equipment according to the present inventioncomprises at least one assembly table for producing single layerelements of brick material and cement mortar, equipment for preparingthe reinforcing iron rods, a concrete mixing plant, facilities forgenerating auxiliary means (electric current, steam, compressed air,etc.) and possibly a service container with offices and personnel roomsas required.

A characteristic of the present invention is that the various equipmentelements are mounted on trailers and/or in containers that can betransported, by road or by rail all the way to the building site wherethe planned building or buildings are to be erected, where the equipmentcan be arranged according to a suitable lay-out plan as required forrationalising the work process.

The equipment elements of the mobile plant are conceived for a number ofproduction functions:

-   -   Using the same assembly tables various element types can be        produced,    -   Panels of various thickness can be produced,    -   On each trailer two operating units including their storage are        transported,    -   Production always is effected at a level above ground, damp and        grimy conditions thus being avoided,    -   Surfaces of up to 250 square meters or 450 square meters,        respectively, can be produced per work day,    -   The same equipment can be applied for traditional work methods,    -   The plant structure is particularly suited for large building        tasks such as e.g. entire developments or settlements, etc.

The mobile plant can be managed technically for production control fromoutside using particular software programs conceived for organisingproduction on a fixed basis, not just for planning but also forproduction control and the assembly of the elements.

The principles described of the present invention refer to an innovativetechnique in the field of building construction based on the productionconcept.

The essential characteristics of the novel method of assembling areknown according to the state of the art e.g. from a particular elementof brick material (the European Patent Application EP-12737729A2 citedabove), using which it was possible already to reach a series ofadvantages described in detail in the document cited.

Practical experience has shown that assembly of all these types of wallor ceiling elements can be effected owing to particular equipmentelements, which can be transported easily to the building sites wherethe equipment is placed and rendered operative within a few hours.

The manufacturing facility is laid out in such a manner that a certainnumber of elements of brick material amalgamated with cement mortar andreinforcing iron can be stored, which are the panel elements ready to beused (transport and mounting).

The assembly concepts shown here thus are aimed at eliminating theinconveniences caused by transports, and by the lack of trainedpersonnel.

The objective of the present invention thus is to be understood as animprovement of the known techniques in building construction, known astraditional, as well as production of prefab elements in stationaryplants.

The result obtained owing to the application of the constructive conceptcited, known from the state of the art, from the element in brickmaterial cited in the EP-1273729A2, permits e.g. assembly of up to 15types of panel elements not only differing from each other but also ofdifferent thickness.

These objectives are met owing to studies of the particular elements ofequipment, used also within the frame of the present invention, andwhich constitute a revalidation of the use of commonly known materialsand yield cost reductions owing to the application of a novelconstruction process.

The mobile plant according to the present invention thus represents theconsequent improvement of the rationalised assembly of elements thatconstitute the prefab element.

Work times required are optimised and independent of inconvenientweather conditions, particularly during winter time, the problemscreated by transports and building sites thus being eliminated.

The present invention thus permits production of large number of panelelements directly on the spot, all of which are obtained at betterquality, profits and speed.

The “mobile” plant preferentially is laid out in the sense of a one waystreet, where the starting materials enter on one side and where theassembled product leaves on the opposite side.

Using the proposed production system with the particular equipment the“mobile” plant offers the following principal advantages:

-   -   Standardised production process for all types of prefab elements        (e.g. the ones described in EP-1273729A2);    -   Possibility of obtaining larger panel dimensions in length and        in width, all inconveniences caused by transports being avoided;    -   Homogenous load bearing structures, or filling or dividing        structures are assembled using one single assembly process for        high quality;    -   A large number of flat panel surfaces are produced without        specialised operators, owing to a controlled production process.    -   Absolute control of the production and of the quality of all        products assembled.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in more detail in the following withreference to illustrated realisation examples. It is shown in the:

FIG. 1 A canopy or roof (tent, transportable roof structure with steelstruts and cover panels, etc.) protecting against adverse weatherinfluences covering the following equipment elements, seen from aboveand from the side;

FIG. 2 Lay-out of the mobile plant with its basic equipment;

FIG. 3 Lay-out of the mobile plant with its basic equipment, seen in asection;

FIG. 4 A schematic plan of the equipment transport;

FIG. 4.1 A schematic plan of operation of the equipment;

FIG. 5 A schematic production plan for the mobile plant;

FIG. 6 A plan, side view and section of an assembly table for producingwalls with double layer elements of brick material, mounted on atrailer, during the transport phase;

FIG. 6.1 A plan, side view and section of an assembly table forproducing walls with double layer elements of brick material, mounted ona trailer, during the working phase on the ground;

FIGS. 7 and 7.1 A plan, side view and section of a container forpreparing reinforcing rods;

FIG. 8 A plan, side view and section of the complete mobile plant forpreparing concrete mortar.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

In the FIG. 1 a canopy A or covering roof is shown in the form of alarge tent 1. It easily can be imagined as a circus tent, but it isobvious that according to the invention any suitable cover structurethat can be dismantled (e.g. a structure of steel struts and coverplates) could be used as well.

The form and the dimensions of the canopy A are chosen in function ofthe size of the mobile plant to be realised. Of importance is just thefact that the canopy can be easily dismantled and transported.

In the FIG. 2 an imaginable lay-out plan is shown of the inventivemobile plant in a practical form of realisation. The reference numbersin the Figure indicate the following working elements:

-   1. Pivotable and tiltable assembly table,-   1.1 Assembly table for tunnel system,-   1.2 Assembly table for pillars,-   1.3 Assembly table for stairs,-   1.4 Various productions,-   1.5 Electric lifting winch.

It is to be noted here that in the FIG. 2 a mobile plant is represented,which is apt to produce a whole series of different elements of brickmaterial. The arrangement of assembly tables 1 through 1.3, requiredaccording to the present invention, thus depends on the type of buildingconstruction to be realised and is easily adapted to the requirements.Also the size of the canopy A is to be chosen according to the specificrequirements that can vary according to the buildings to be erected, beit an industrial building (large tent) or an urban residential buildingor a multi-storey building, etc.

A water tank reservoir is indicated with 2 (always required except incases where a sufficient local water supply can be relied on, while 3indicates a concrete mixer.

In the FIGS. 3.1 and 3.2 each a deposit for inert materials and a cementmortar distributor are shown, i.e. elements for work rationalisation inthe mobile plant. In the FIG. 4 a storage deposit area is shown for thebrick elements required for producing the various panel elements ofbrick material and mortar (compare the description in the EP-1273729A2cited), whereas in the FIG. 5.1 a shop for preparing reinforcing ironrods for the panel elements of brick material and mortar is shown. Inthe FIG. 6 an installation is shown for generating auxiliary means(steam, electric current, compressed air, etc.), and in the FIG. 7 acontainer is shown for offices, sanitary installations, dormitories forworkers, canteen, etc.

Evidently the presence of these services can depend on the localrequirements where the building activity takes place. Conditionspermitting dormitories for workers thus will be dispensed with, etc.,and the facilities available locally will be relied on. In any case themobile plant can be provided with all these services in such a mannerthat it can operate autonomously with respect to the working conditionsin its environment. It is to be noted here also, that in the example ofpractical realisation according to the FIG. 2, also transportable floorplanks 10 are provided permitting easier transport of the panel elementsproduced, and a lifting winch 11 for facilitating internal transport. Itis clear that provision of such transport equipment elements will beadapted to each task of the mobile plant, of which in the FIG. 2 just apractical example is shown. All and any variation of the lay-outdescribed here of a mobile plant for producing prefab elements must beconsidered as fitting into the frame of the present invention, under thecondition that every equipment element, which is part of the mobileplant, be mounted on trailers and/or in containers transportable by roador by rail to the building site. This actually is the basiccharacteristic of the present invention.

In the FIG. 3 the lay-out of the mobile plant according to the FIG. 2 isshown schematically in a section demonstrating that the individualequipment elements 1, 1.1, 1.2, 1.3 are mounted onto trailers and thuscan be easily transported by road. In the FIG. 4 the base plan oftransport of the equipment shows that the assembly tables 1, . . . 1.3can be transported by road in their transport configuration. An analoguesolution easily can be imagined for transport by rail.

In the FIG. 4.1 a particular preferred realisation form of the presentinvention is shown, in which the assembly table 1 is mounted on atrailer 12 (compare also the FIG. 4) of a truck (not shown) and isprovided with a horizontal hinge 13 permitting pivoting of the assemblytable 1 from a vertical filling and transport position (FIG. 4) into ahorizontal working and unpacking position indicated in the FIG. 4.1.This system facilitates work in the mobile plant.

In the FIG. 5 then a possible block plan is shown of the inventivemobile plant. This illustration is self-explanatory and shows the baseconstitution of the inventive mobile plant.

In the FIG. 6 a plan, a side view and a section are shown of an assemblytable 1 for producing wall panels with double layer elements of brickmaterial on the trailer 12, during transport, whereas in the FIG. 6.1 aplan, a side view and a section are shown of an assembly table 1 forproducing wall panels with double layer elements of brick material onthe trailer 12, during the working phase on the ground.

In the FIG. 7 a plan, a side view and a section are shown of a containerfor preparing the reinforcing iron rods for producing the panel elementsof brick material and mortar. Also this container is provided with wallsthat tilt down and can be opened, which container contains e.g. thefollowing items: reinforcing iron bender 15 (left), work bench 16,reinforcing iron bender 17 (right), reinforcing net cutter 18,reinforcing net bender 19.

In the FIG. 8 finally the complete concrete mixer plant is shown in aplan and in a side view, which also is mounted on a trailer 12 for easytransport to the building site according to the teachings of the presentinvention. In this Figure, shown at the upper right, a possible locationis indicated of the equipment element 3 under the canopy structure A.

According to a preferred realisation form of the present invention it isprovided that the equipment elements 1 through 6 be disposed under thecanopy structure A in such a manner that the production of the panelelements of brick material and mortar is effected according to theone-way principle, where the starting materials enter at one side of thecanopy structure A whereas the assembled panel elements of brickmaterial and mortar emerge at the opposite side of the canopy structureA. This can be seen e.g. e.g. from the schematic block plan according tothe FIG. 5, where the starting materials (brick material elements, etc.)enter at the left hand side whereas the finished panel elements emerge(towards the building site) at the right hand side in a straight linearflow. This procedure, rationalising the production process, certainly isnot new as such, but is novel and original as applied in the frameworkof a mobile plant like the inventive one described.

The advantages of the inventive mobile plant basically are therationalisation of the construction of residential and industrialbuildings, especially if large building projects are dealt with (e.g.building of new settlements or residential developments for tourists, orrebuilding after nature disasters, etc.) with corresponding savings inbuilding cost, owing to the fact that after completion of the buildingsthe mobile plant easily can be dismantled and be transported to anotherbuilding site. Not to be neglected are the ecologic advantages owing tothe elimination of transports otherwise required for bringing personneland prefab panel elements built elsewhere to the installation site, incases over hundreds of kilometres.

REFERENCE NUMERALS

-   A canopy (tent, temporary hall)-   1,1.1,1.2,1.3 pivotable and tiltable assembly table-   2 water tank, reservoir-   3 concrete mixer plant-   4 storage area of brick elements-   5 office and storage-   5.1 installation for preparing reinforcing irons-   6 plant for generating auxiliary means-   7 containers for personnel and management-   10 transportable foot planks-   11 lifting winch-   12 trailer-   13 horizontal assembly table hinge-   14 container for preparing reinforcing items-   15 reinforcing iron bender (left)-   16 work bench-   17 reinforcing iron bender (right)-   18 reinforcing net cutter-   19 reinforcing net bender-   20 storage area for assembled elements

1. Mobile plant for producing prefab elements of brick material andcement mortar for the construction of residential and industrialbuildings comprising at least the following equipment elements: acovering canopy (A) as a roof that can be dismantled, one or moreassembly tables (1, 1.1, 1.2, 1.3) for producing panel elements of brickmaterial and cement mortar, a plant (14) for preparing the reinforcingirons for the panel elements of brick material an cement mortar, aconcrete mixing plant (3) for preparing the cement mortar to be suppliedto the assembly tables (1,
 1. 1, 1.2, 1.3), and/or a station (6) forgenerating auxiliary means such as steam, electric current, compressedair, with the corresponding pumps, and/or a service container (7) foroffices, sanitary stations, dormitories for workers, and the canteen,where the individual equipment elements are mounted on trailers and/orin containers transportable by road or by rail to the building sitewhere the buildings are to be realised, and which can be arrangedaccording to a suitable lay-out plan for producing prefab panelelements.
 2. Mobile plant according to the claim 1, characterised inthat the covering canopy is a large tent (A).
 3. Mobile plant accordingto the claim 1 characterised in that the covering canopy is a steelstrut structure with covering plates, that can dismantled.
 4. Mobileplant according to the claim 1, characterised in that the equipmentelements (1 through 6) are arranged within the covering canopy (A) insuch a manner that the production of the panel elements of brickmaterial and concrete mortar can be effected according to a principle ofone-way direction, the starting materials entering at one side of thecanopy (A) and the assembled panel elements emerging at the oppositeside of the covering canopy (A).
 5. Mobile plant according to the claim1, characterised in that the assembly table (1) is mounted on a trailer(12) of a truck and is provided with a horizontal hinge (13) permittingpivoting of the assembly table (1) from a vertical transport and fillingposition to a horizontal working and unpacking position.
 6. Mobile plantaccording to the claim 5, characterised in that on a trailer (12) twoassembly tables (1, 1.1) are mounted on each longitudinal side of thetrailer (12), each of which can be pivoted about its own horizontalhinge (13) from a of the a vertical transporting and filling position toa horizontal working and unpacking position.
 7. Mobile plant accordingto the claim 5, characterised in that the vertical filling position ofthe assembly table also is its transporting position on a trailer (12)of a truck.
 8. Mobile plant according to the claim 1, characterised inthat it contains different types of assembly tables such as: assemblytables for flat panels (1,
 1. 1), assembly tables for posts andpilasters (1.2) assembly tables for stairs (1.3), other types ofassembly tables for producing different element types (1.4).
 9. Mobileplant according to the claim 1, characterised in that within thecovering canopy (A) or in its close vicinity furthermore a storage area(20) is provided for the assembled individual elements of brick materialand mortar.
 10. Mobile plant according to the claim 6, characterised inthat the vertical filling position of the assembly table also is itstransporting position on a trailer (12) of a truck.